COMPOSITION FOR MATERIAL FOR LIQUID METAL DEPOSITION OR ADDITIVE MANUFACTURING, METHOD AND PRODUCT

Abstract

A composition of a nickel based alloy mixture which can be used for welding via especially liquid metal deposition or as a powder bed of an additive manufacturing method. A metallic powder mixture includes (in wt %): a cobalt (Co) or nickel (Ni) based super alloy with a content of 20% to 60%, a NiCoCrAlY-composition with a content of 70% to 30% and a metallic braze material with a content between 10% to 5%. The melting point of the braze material is at least 10K lower than the melting point of the nickel or cobalt based superalloy.

Claims

1. A metallic powder mixture, especially usable for build up via liquid metal deposition or any additive manufacturing method, comprising (in wt %): especially consisting of (in wt %): a cobalt (Co) or nickel (Ni) based super alloy with a content of 20% to 60%, a NiCoCrAlY-composition with a content of 70% to 30% and a metallic braze material with a content between 10% to 5%, wherein the melting point of the braze material at least 10K, especially at least 20K, lower than the melting point of the nickel or cobalt based superalloy, especially the powder mixture consists of 3 powders with different compositions.

2. The metallic powder mixture according to claim 1, comprising (in wt %): especially consisting of (in wt %): TABLE-US-00006 Nickel (Ni) from 51.00% to 58.00%  Carbon (C) from 0.02% to 0.05% Chromium (Cr) from 11.00% to 15.00%  Cobalt (Co) from 14.00% to 21.00%   Molybdenum (Mo) from 0.05% to 0.35% especially from 0.01% to 0.30% Tungsten (W) from 1.80% to 5.80% Titan (Ti) from 0.10% to 0.50% Aluminum (Al) from 6.50% to 8.50% Boron (B) from 0.05% to 0.10% especially       0.08% Tantalum (Ta) from 0.80% to 2.20% Hafnium (Hf) from 0.20% to 0.80% Yttrium (Y) from 0.05% to 0.25% especially from 0.09% to 0.21% Rhenium (Re)  from 0.40% to 1.10%.

3. The metallic powder mixture according to claim 1, wherein the nickel (Ni) base superalloy comprises (in wt %), especially consists of (in wt %): TABLE-US-00007 Carbon (C) 0.05%-0.20% especially 0.07%-0.17% Chromium (Cr)  8.0%-23.0% especially 12.0%-23.0% Cobalt (Co)  8.0%-19.0% especially  9.0%-10.0% very especially 18.0%-19.0% Tungsten (W)  2.0%-10.0% especially 2.0%-4.5% very especially  9.0%-10.0% Titan (Ti) 0.6%-5.0% Aluminum (Al) 1.0%-6.0% Boron (B) 0.005%-0.02%  especially 0.006%-0.015% optionally Molybdenum (Mo) 0.0%-4.5% especially 0.50%-4.0%  Tantalum (Ta) 0.0%-4.5% especially 1.0%-4.5% Hafnium (Hf) 0.6%-1.5% Zirconium (Zr) 0.02%-0.12% Niobium (Nb) 0.5%-1.0% especially no Yttrium (Y) and/or no Rhenium (Re), remainder Nickel (Ni).

4. The metallic powder mixture according to claim 1, wherein the nickel (Ni) base superalloy comprises (in wt %), especially consists of (in wt %): TABLE-US-00008 Nickel (Ni) 61.6% Carbon (C) 0.08% Chromium (Cr) 8.25% Cobalt (Co) 9.25% Molybdenum (Mo) 0.50% Tungsten (W) 9.50% Titan (Ti) 0.75% Aluminum (Al) 5.55% Boron (B) 0.02% Tantalum (Ta) 3.20% Hafnium (Hf) 1.30%, especially no Yttrium (Y) and/or no Rhenium (Re).

5. The metallic powder mixture according to claim 1, wherein the nickel based super alloy is selected from alloy247, Inconel625, Rene 80 and/or Merl72, especially alloy247.

6. The metallic powder mixture according to claim 1, wherein the braze alloy comprises (in wt %): especially consists of (in wt %): TABLE-US-00009 Nickel (Ni) 40%-70%  Chromium (Cr) 8.0%-23.0% Cobalt (Co) 5.0%-20.0% Aluminum (Al) 1.0%-10.0% Boron (B) 0.5%-4.00% optionally Tantalum (Ta) 1.0%-4.0% Molybdenum (Mo) 0.0%-5.0% Hafnium (Hf) 0.05%-0.09% Tungsten (W)  2.0%-10.0% Titan (Ti) 0.5%-5.0% especially no Yttrium (Y), and/or no Rhenium (Re), and/or no Carbon (C).

7. The metallic powder mixture according to claim 1, wherein the braze alloy comprises (in wt %): especially consists of (in wt %): TABLE-US-00010 Nickel (Ni) 69.2% Chromium (Cr) 14.0% Cobalt (Co) 10.0% Aluminum (Al)  3.5% Boron (B) 0.75% Tantalum (Ta)  2.5% Hafnium (Hf)  0.06%, especially no Yttrium (Y) and/or no Tungsten (W), and/or no Titan (Ti), and/or no Molybdenum (Mo), and/or no Rhenium (Re), and/or no Carbon (C).

8. The metallic powder mixture according to claim 1, wherein the melt depressant Boron (B) is at least partially replaced by or it is additionally added: Silicon (Si) and/or Magnesium (Mg) and/or Mangan (Mn).

9. The metallic powder mixture according to claim 1, wherein the braze material is a nickel based alloy with at least 0.5 wt % Boron (B), especially at least 0.7 wt % Boron (B) and/or at least 1.0 wt % Silicon (Si), especially at least 1.5 wt % Silicon (Si) and/or at least 2.0 wt % Magnesium (Mg), very especially the braze alloy Amdry DF-4B.

10. The metallic powder mixture according to claim 1, wherein NiCoCrAlY consists of NiCoCrAlY and optionally Tantalum (Ta), Rhenium (Re), Iron (Fe) and/or Silicon (Si).

11. The metallic powder mixture according to claim 1, wherein the NiCoCrAlY composition comprises (in wt %): especially consists of (in wt %): 14%-22% Chromium (Cr) 9.0%-11.5% Aluminum (Al) 0.3%-0.5% Yttrium (Y) 11%-26% Cobalt (Co) 0%-1.0% Silicon (Si), especially 0.1%-1.0% Silicon (Si), 0%-2.5% Rhenium (Re) or and remainder Nickel (Ni).

12. The metallic powder mixture according to claim 1, wherein the NiCoCrALY composition comprises (in wt %): especially consists of (in wt %): TABLE-US-00011 20%-22% Chromium (Cr) 10.5%-11.5% Aluminum (Al) 0.3%-0.5% Yttrium (Y) 1.5%-2.5% Rhenium (Re) or between 0.5%-1.5% Rhenium 11%-13% Cobalt (Co) and remainder Nickel.

13. The metallic powder mixture according to claim 1, wherein the NiCoCrAlY composition comprises (in wt %): especially consists of (in wt %): TABLE-US-00012 15%-21%  Chromium (Cr) 24%-26%  Cobalt (Co) 9.0%-11.5% Aluminum (Al) 0.05%-0.7%   Yttrium (Y) 0.5%-2.0%  Rhenium (Re) and remainder Nickel.

14. The metallic powder mixture according to claim 1, wherein the NiCoCrAlY composition comprises (in wt %): especially consists of (in wt %): TABLE-US-00013 22%-24% Cobalt (Co) 14%-16% Chromium (Cr) 10.5%-11.5% Aluminum (Al) 0.2%-0.4% Yttrium (Y), optional 0.3%-0.9% Tantalum (Ta) and remainder Nickel (Ni).

15. A method to build up metallic material, comprising: building up a metallic powder mixture of claim 1.

16. The method according to claim 15, wherein the building up of the metallic powder mixture is used for welding using powder cladding, wire welding or for additive manufacturing using powder beds, especially SLM, SLS.

17. A product, comprising: a metallic powder mixture according to claim 1.

18. The product according to claim 17, wherein first directly on the substrate a layer of a mixture consisting of a NiCoCrAlY, and a nickel or cobalt based superalloy is applied on the substrate, and then the layers of the metallic powder mixture are applied.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0042] FIG. 1 shows a method how to apply the inventive material during welding and FIG. 2 shows a schematic arrangement to use the inventive powder for additive manufacturing, especially via laser.

DETAILED DESCRIPTION OF INVENTION

[0043] The description and the figures are only examples of the invention.

[0044] This method and the material can be used to build up totally new component starting on a base plate or to repair an existing substrate 4 which both means a build up of material.

[0045] The build up of material is necessary to erosion or cracks which have been removed. In this case, only for example, a blade tip is repaired by building up the material onto a blade tip 7. The surface 10 of the substrate 4 reveals the base on which the material is applied on. The material 16 is applied via a nozzle 13 which is connected to a powder supply 19 is an inventive material. The nozzle 13 also includes a laser which together with the powder 16 is used for welding by melting the powder via a laser beam (not shown).

[0046] The inventive material can also be produced as a rod and or a wire and can be used via wire welding.

[0047] In FIG. 2 another application of the inventive material is shown.

[0048] Here a selective laser melting process (also electron beams can be used instead of a laser) wherein a powder bed 22 with the inventive powder mixture is used to create a totally new component or even to repair a substrate 4.

[0049] The substrate 4 is totally inside the powder bed 22 and a laser 25 with a laser beam 28 is used to melt or to sinter partially a powder where a material build up onto the substrate 4 where it is needed or wanted.

[0050] The inventive material is a metallic powder mixture of three different powders.

[0051] Especially the powder mixture comprises alloy 247 or generally a nickel based super alloy and a NiCoCrAlY, a braze alloy which has at least a melting point at least 20K lower than the nickel based super alloy.

[0052] Further examples for the nickel based super alloy are listed in FIG. 3.

[0053] NiCoCrAlY can also comprise optionally additions like Rhenium (Re), Tantalum (Ta) and/or Silicon (Si), very especial only these ones.

[0054] Another example is, wherein first direct on the substrate a layer of a mixture consisting of a NiCoCrAlY especially according to dependent claims and a nickel or cobalt based superalloy, especially according to dependent claims is applied and then layers of a mixture according to certain claims.